Coordinating installation and connection of a motor control center subunit having moveable line contacts
A system and method are provided for coordinating the installation and removal a motor control center subunit with the power connection and interruption thereof. A system of interlocks and indicators causes an operator to install a motor control center subunit into a motor control center, and connect supply and control power thereto, in a particular order. Embodiments of the invention may prevent actuation of line contacts of the bucket, and shield the line contacts, until the bucket is fully installed in the motor control center. Other embodiments also prevent circuit breaker closure until the line contacts are engaged with a bus of the motor control center.
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The present invention is a continuation-in-part of and claims the benefit of U.S. Ser. No. 11/625,088, filed on Jan. 19, 2007, which claims the benefit of U.S. provisional application Ser. No. 60/833,380, filed Jul. 26, 2006, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTIONThe present invention relates generally to motor control systems, and more particularly, to a motor control center subunit having an interlock system which governs the connection of motor control components to supply power. In one embodiment, the system and method described herein coordinate the connection of supply power to the motor control components to occur only after full installation of the motor control center subunit into the motor control center.
A motor control center is a multi-compartment steel enclosure with a bus system to distribute electrical power, on a common bus system, to a plurality of individual motor control units mountable within the compartments. The individual motor control center subunits are commonly referred to as “buckets” and are typically constructed to be removable, pull-out units that have, or are installed behind, individual sealed doors on the motor control center enclosure. These buckets may contain various motor control and motor protection components such as motor controllers, starters, contactor assemblies, overload relays, circuit breakers, motor circuit protectors, various disconnects, and similar devices for electric motors. The buckets connect to the supply power lines of the motor control center and conduct supply power to the line side of the motor control devices, for operation of motors. Motor control centers are most often used in factories and industrial facilities which utilize high power electrical motors, pumps, and other loads.
Typically, when installing or removing motor control center buckets, the power supply lines are connected. To remove such a bucket, a deadfront door of the bucket or of the motor control center is opened and an operator manually pulls on the bucket to separate the primary disconnects, or “stabs,” from the bus system, thereby disconnecting the power supply. Installation of a bucket is accomplished in a similar manner, wherein the operator manually pushes the bucket into a compartment of the motor control center to engage the bucket stabs with the bus system, thus connecting the system to supply power. The line connections or stabs may be difficult to maneuver manually when an operator is supporting the entire bucket or when the stabs are not visible.
Attempts have been made to improve upon the manual installation and disconnection of motor control center buckets and supply power connections from live supply power lines, risers, and/or a vertical bus of a motor control center. Other systems have employed pivotable handles inside the buckets to pivot line connectors to and from supply lines. However, many of these systems require that the bucket or compartment door be open to manipulate the handles and line stabs.
It would therefore be desirable to design a motor control center bucket assembly that overcomes the aforementioned drawbacks. Thus, it would be desirable to provide for remote connection or disconnection of the line stabs of a bucket to the power supply lines or bus of a motor control center from a distance. In the event of an arc or arc flash, any heated gas, flame, and/or the arc itself should preferably be contained behind the bucket compartment door or “deadfront.”
BRIEF DESCRIPTION OF THE INVENTIONThe present invention provides a system and method for installing a motor control center subunit or bucket into a motor control center and electrically connecting motor control components of the bucket to a power supply. The system and method utilize moveable line stabs to engage the power supply (such as a series of bus bars) after the bucket has been secured in the motor control center, in order to contain potential arc flashes. An arrangement of interlocks coordinates the connection of supply power with installation and removal of the bucket.
Therefore, in accordance with one aspect of the present invention, a motor control center subunit is disclosed. The subunit includes a housing configured to fit within a motor control center and an actuating mechanism attached to the housing and constructed to move at least one conductive contact to engage and disengage a supply power of the motor control center. The subunit also includes an interlock system arranged to coordinate installation of the subunit housing into the motor control center with connection of the supply power to motor control components of the subunit housing.
In accordance with another aspect of the invention, a motor control center is provided having a frame, a subunit, an actuating mechanism, and an interlock. The motor control center frame has at least one compartment into which the motor control center's subunit is constructed to seat. The actuating mechanism is attached to the subunit to control movement of a plurality of conductive contacts. However, the interlock is configured to prevent actuation of the actuating mechanism until the motor control center subunit is seated in the compartment.
According to a further aspect of the invention, a method of manufacturing an interlock system for a motor control center is disclosed. The method includes constructing a motor control center subunit to seat within a motor control center. Engagement of a plurality of movable contacts of the motor control center subunit with a supply bus of the motor control center is restricted, dependent upon a state of at least one interlock.
Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings.
The drawings illustrate one preferred embodiment presently contemplated for carrying out the invention.
In the drawings:
The following description makes reference to supply power, supply power lines, motor power, load power, line power, and the like. It is appreciated that such terms may refer to a variety of both common and uniquely conditioned voltage and current characteristics, including but not limited to, three phase AC power, single phase AC power, DC power, multiple DC power lines, or any combination thereof. Such power characteristics will be generally referred to as being provided on a bus, supply line, or riser of a motor control center. However, it is appreciated that the present invention may find applicability in other power connectivity configurations, adapted or apart from motor control centers. An example of supply power commonly used in motor control centers is 480V three-phase AC power distributed over three separate supply bus bars. In addition, references to “motor control components” shall be understood to include the various types of devices and control components which may be housed in a motor control center bucket for connection to the supply power. Such devices and components include contactors, relays, motor controllers, disconnects, circuit protective devices, and the like.
Referring to
In other embodiments, a crank 300 for actuating an actuating assembly 302 may include a flange 304 which abuts a front door 306 of a bucket 13 when the crank 300 is connected to the actuating assembly 302 thereof. Because the flange 304 extends further than the actuating assembly 302 and overlaps front door 306, flange 304 acts as an interlock to prevent door 306 from opening when the crank 300 is connected for operation of actuating assembly 302.
As an alternative to, or in combination with, using a hand crank, a motor drive 308 may be used to operate an actuating assembly 310 of a bucket 17. Such a motor drive 308 may be connected permanently or removably to actuating assembly 310. Preferably, motor drive 308 is a DC motor remotely operable from distances of 10-50 ft, whether wirelessly or with a wired controller. Motor drive 308 may be powered by a battery or by an electrical connection with motor control center 10, such as via the control power contact 44 shown in
Referring now to
When slide 32 of line contact actuator 31 is moved aside, an opening 36 is exposed. Opening 36 preferably has a unique configuration to accept a specialized crank 34 (as shown in
Bucket 16 also includes a number of conductive contacts or stabs 44, 46, 48, 50. Control power contact 44 is preferably fixedly attached to the rear of bucket 16, whereas supply power stabs 46, 48, 50 are moveable with respect to bucket 16. However, it is appreciated that control power contact 44 may also be moveable in a similar manner to line power stabs 46, 48, 50. Control power contact 44 is of a suitable construction to conduct a control power (typically a few volts) to motor control components (not shown) disposed within bucket 16. In embodiments where control power contact 44 is permanently positioned at the rear of bucket 16, control power contact 44 will engage a control power supply line or bus upon installation of bucket 16 into a motor control center.
Supply power stabs 46, 48, 50, on the other hand, do not initially engage supply power lines or buses when bucket 16 is installed into a motor control center. Rather, stabs 46, 48, 50 are initially in retracted position 42, disposed inside bucket 16. One skilled in the art will appreciate that a number of configurations of supply power stabs 46, 48, 50 may be utilized. In the embodiment shown, stabs 46, 48, 50 are shaped to grasp about a supply line, bus, or riser of the motor control center 10 of
The stab assembly 58, in addition to stabs 46, 48, 50, also includes a stab bracket 59 to which the stabs 46, 48, 50 are attached. Stab bracket 59 holds stabs 46, 48, 50 in an orientation for subsequent engagement with the supply power lines or buses of motor control center 10 of
Referring now to
Also shown in
For removal of bucket 16, circuit breaker 30 is opened, disconnecting supply power to the motor control devices (not shown) of bucket 16. Stabs 46, 48, 50 may then be retracted from bus bars 88, 90, 92 by a reverse motion of rotary shaft 84. Once stabs 46, 48, 50 pass shutters 56, the right and left portions 62-72 thereof will automatically close together to isolate the stabs from bus bars 88, 90, 92. Preferably, the shutter portions 62-72 and all or some of the housing panels, including front panel 18 and a rear panel (not shown), of bucket 16 are formed of plastic or another insulating material. After stabs 46, 48, 50 have been fully retracted, automatic latch 60 will release from engagement with the motor control center, and an operator may then slide bucket 16 out of the motor control center.
Referring now to
Referring now to
Referring now to
In the embodiment shown, circuit breaker interlock 316 includes microswitch 94, which gates the operation of circuit breaker 30.
Also shown in
As discussed above, the advancement of stabs 46, 48, 50 to the extended position 45 separates a number of shutter portions, including shutter portion 62. In the embodiment shown in
Referring now to
Circuit breaker interlock 316 is shown in an alternate configuration, having an upward-sloping end 350 near door 18 and a pair of vertical tines 352 and one horizontal tine 354 at an opposite end. Vertical tines 352 are engaged by a stab guide 96 (
Interlock plate 322 has a projection 362 extending therefrom to fin 346 of circuit breaker handle 30. Projection 362 is integrally formed with, or affixed to, plate 322, and is configured to move side-to-side with plate 322, when upward-sloping end 350 of circuit breaker interlock 316 is not inserted in opening 356. Projection 362 has a pair of tines 348 which extend outwardly therefrom, on either side of fin 346. Therefore, when plate 322 is prevented from moving, tines 348 prevent fin 346 from rotating, thereby preventing an operator from turning circuit breaker handle 30. In this manner, circuit breaker interlock 316 prevents a user from closing circuit breaker handle 30 until the stabs of bucket 16 are fully extended. It is understood that circuit breaker interlock 316, interlock plate 322, and associated components may have a number of shapes, orientations, and configurations which allow for the functionality described herein.
When an operator closes circuit breaker handle 30, fin 346 impinges upon the tines 348 of projection 362 in a counter-clockwise direction. The force of fin 346 on tines 348 causes projection 362 and interlock plate 322 to shift to the left, as orientated in
Also shown in
Similarly, rod 76 of shutter indicator 26 (
Referring now to
Thus, an interlock system has been disclosed, in a number of embodiments, which coordinates the installation and power connections of a motor control center subunit or bucket. When a user slides the bucket completely into the enclosure of a motor control center, the line contacts or stabs of the bucket are shielded from the bus bars. Once the bucket is inserted into the enclosure, the front door of the bucket must be closed and the circuit breaker must be off/open in order for the operator to have access to the stab actuating mechanism. Additionally, a user may have to unlock a padlock and latch to gain access to the slide and/or actuating mechanism. Once the actuating mechanism opening is exposed, a crank (or motor drive) may be connected thereto. The stab indicator will show a green “stabs-disengaged” status, and the shutter indicator will show a green “shutters-closed” status. As the stabs are initially advanced, an automatic retention latch is triggered to engage the frame of the motor control center and prevent removal of the bucket therefrom. Also, a micro-switch is activated by the initial advancement of the stabs, turning on control power for the motor control components inside the bucket. When the line stabs reach the back of the bucket, but have not moved past the shielding shutters, the bucket is in the “test” position. The stab indicator will show a yellow “test” status, and the shutter indicator will still show a green “shutters-closed” status. When the stabs are advanced further, they will open the shutters, causing the shutter indicator to show a red “shutters-open” status. When the shutters reach and engage the bus bars, the stab indicator will show a red “stabs-engaged” status and the circuit breaker interlock will be tripped. At this point, the circuit breaker will be permitted to close once the user removes the crank or motor from the actuating mechanism. When a user closes the circuit breaker, access to the actuating mechanism will be obscured by a circuit breaker interlock plate. The circuit breaker handle and/or the actuating mechanism slide can be padlocked in place at this point to maintain the engaged, operating state now achieved. Moreover, it is understood that the interlock system thus disclosed also coordinates the power disconnection and removal of the bucket from the motor control center, by reverse operation of the aforementioned interlocks and indicators.
Accordingly, one embodiment of the present invention includes a motor control center subunit having a subunit housing, an actuating mechanism, and an interlock system. The subunit housing is configured to fit within a motor control center. The actuating mechanism is attached to the subunit housing and is constructed to move at least one conductive contact to engage and disengage a supply power of the motor control center. The interlock system is arranged to coordinate installation of the subunit housing into the motor control center with connection of the supply power to motor control components of the subunit housing.
In accordance with another embodiment of present invention, a motor control center includes a frame having at least one compartment and a subunit constructed to seat in the at least one compartment of the motor control center frame. An actuating mechanism is attached to the motor control center subunit to control movement of a plurality of conductive contacts and an interlock is configured to prevent actuation of the actuating mechanism until the motor control center subunit is seated in at least one compartment.
In another embodiment of the present invention, a method of manufacturing an interlock system for a motor control center is provided. The method includes constructing a motor control center subunit to seat within a motor control center and restricting engagement of a plurality of movable contacts of the subunit with a supply bus of the motor control center dependent upon a state of at least one interlock.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
Claims
1. A motor control center subunit comprising:
- a subunit housing configured to fit within a motor control center;
- an actuating mechanism positioned within the subunit housing and constructed to move at least one conductive contact to engage and disengage a supply bus of the motor control center; and
- a control interlock assembly arranged within the subunit housing to: engage the actuating mechanism when the at least one conductive contact is disengaged, wherein engagement between the actuating mechanism and the control interlock assembly prevents actuation of a circuit breaker from outside the subunit housing; and prevent access to an opening in the subunit housing when the circuit breaker is closed to prevent actuation of the actuating mechanism.
2. The motor control center subunit of claim 1 wherein the control interlock assembly comprises a microswitch positioned within the subunit housing to sense contact with the actuating mechanism and electrically enable closure of the circuit breaker when the least one conductive contact is engaged with the supply bus.
3. The motor control center subunit of claim 1 wherein the control interlock assembly comprises:
- a slidable plate positioned at an interior surface of the subunit housing, the slidable plate interconnected with the circuit breaker; and
- an interlock plate coupled to the actuating mechanism, the interlock plate having a sloped end that engages with the slidable plate to prevent closure of the circuit breaker when the at least one conductive contact is disengaged.
4. The motor control center subunit of claim 3 wherein the sloped end of the interlock plate is sized to engage an opening in the slidable plate to prevent movement thereof.
5. The motor control center subunit of claim 3 wherein the slidable plate comprises a protrusion positioned to engage the sloped end of the interlock plate when the at least one conductive contact is disengaged.
6. The motor control center subunit of claim 3 wherein the slidable plate is constructed to move from a first position to a second position upon closure of the circuit breaker, and wherein the slidable plate permits access to the actuating mechanism in the first position and prevents access to the actuating mechanism in the second position.
7. The motor control center subunit of claim 1 further comprising:
- a contacts indicator coupled to a front surface of the subunit housing; and
- a cam coupled between the actuating mechanism and the contacts indicator and configured to sense a location status of the at least one conductive contact within the subunit housing.
8. The motor control center subunit of claim 1 wherein the control interlock assembly further comprises a hand crank coupled to the actuating mechanism to control movement of the actuating mechanism, the hand crank constructed to remain in a locked position until the motor control center subunit is fully installed in the motor control center.
9. The motor control center subunit of claim 1 further comprising a motor drive coupled to the actuating mechanism to drive the actuating mechanism.
10. The motor control center subunit of claim 9 wherein the control interlock assembly further comprises a motor drive control circuit designed to prevent activation of the motor drive until the subunit housing is fully installed in the motor control center.
11. The motor control center subunit of claim 1 further comprising a control power switch positioned within the subunit housing to sense a position of the actuating mechanism and supply a control power to motor control components of the subunit housing only when the at least one conductive contact is fully engaged.
12. The motor control center subunit of claim 1 further comprising a door interlock panel attached to a front surface of the subunit housing and moveable between a first position and a second position;
- wherein the door interlock panel is positioned to extend through an opening in a door of the subunit housing when the door interlock panel is in the first position; and
- wherein the door interlock panel is sized to engage with the door of the subunit housing when in the second position.
13. The motor control center subunit of claim 12 wherein the door interlock panel has an opening positioned therein such that when the door interlock panel is in the second position the opening in the door interlock panel aligns with the opening in the subunit housing.
14. A motor control center subunit comprising:
- a housing constructed to seat in a compartment of a motor control center;
- an engagement mechanism attached to the motor control center subunit to control movement of a plurality of conductive contacts between a retracted position and an extended position, wherein the plurality of conductive contacts are disengaged from a power supply in the retracted position and engaged with the power supply in the extended position; and
- an interlock assembly coupled to the engagement mechanism, the interlock assembly constructed to: block access to the engagement mechanism when a circuit breaker is closed to prevent movement of the plurality of conductive contacts from the extended position to the retracted position; prevent closure of the circuit breaker when the plurality of conductive contacts are in the retracted position; and mechanically enable closure of the circuit breaker only when the plurality of conductive contacts are in the extended position.
15. The motor control center subunit of claim 14 wherein the interlock assembly comprises an interlock plate positioned at an interior surface of the housing, the interlock plate constructed to be moveable between a first position that prevents access to the engagement mechanism and a second position that allows access to the engagement mechanism.
16. The motor control center subunit of claim 15 wherein the interlock plate comprises a projection that engages a surface of the circuit breaker and prevents closure of the circuit breaker when the plurality of conductive contacts are in the retracted position.
17. The motor control center subunit of claim 15 wherein the interlock assembly further comprises a slidable plate coupled to the engagement mechanism and configured to translate therewith, such that when the plurality of conductive contacts are in the retracted position the slidable plate interferes with the interlock plate.
18. The motor control center subunit of claim 14 further comprising a motorized actuator coupled to the engagement mechanism to translate the plurality of conductive contacts between the retracted position and the extended position.
19. The motor control center subunit of claim 18 wherein the interlock assembly comprises a motor drive control circuit arranged within the motor control center subunit to prevent actuation of the motorized actuator until the motor control center subunit is fully installed in the compartment of the motor control center.
20. The motor control center subunit of claim 14 wherein the interlock assembly further comprises a slide positioned on a front panel of the housing, the slide movable between a first position to allow access to the actuating mechanism and a second position to prevent access to the actuating mechanism.
21. The motor control center subunit of claim 20 wherein the slide is constructed to engage a door of the housing and prevent opening of the door when in the first position.
22. A control module for a motor control center comprising:
- a control module housing fully insertable within a frame of the motor control center, the control module housing having at least one line contact therein;
- a line contacts actuator for engaging the at least one line contact with a line power from the motor control center;
- an interlock assembly positioned to engage the line contacts actuator such that movement of the at least one line contact causes the interlock assembly to move between an unengaged position and an engaged position;
- wherein the interlock assembly engages a first surface of the frame of the motor control center and prevents removal of the control module housing from the motor control center when the at least one line contact is engaged with the line power; and
- wherein the interlock assembly engages a second surface of the motor control center to prevent insertion of the control module into the motor control center when the at least one line contact is extended and unengaged with the line power.
23. The control module of claim 22 wherein the interlock assembly comprises a rotatable latch coupled to the control module housing and engagable with the frame of the motor control center.
24. The control module of claim 23 wherein the rotatable latch is constructed to automatically trigger to engage the frame of the motor control center when the at least one line contact is advanced toward the line power.
25. The control module of claim 23 wherein the rotatable latch is constructed to automatically engage with the frame of the motor control center when the at least one line contact is extended and automatically disengage with the frame of the motor control center when the at least one line contact is disengaged.
26. The control module of claim 23 wherein the interlock system further comprises a control power switch positioned to be activated by movement of the line contacts actuator, the control power switch configured to selectively provide a control power to motor control components of the subunit housing.
27. The control module of claim 22 further comprising a manually drivable handle for driving the line contacts actuator, the manually drivable handle having a flange that overlaps a door of the control module housing when the manually drivable handle is connected to the line contacts actuator.
28. The control module of claim 23 wherein the interlock assembly further comprises a moveable slide positioned on a front surface of the control module housing to selectively obstruct and permit access to an opening in the control module housing, the moveable slide having a surface that engages with a door of the control module housing when permitting access to the opening.
29. The control module of claim 23 further comprising an isolator assembly disposed within the control module housing to electrically shield the at least one line contact.
30. The control module of claim 23 further comprising a contact status indicator disposed on an exterior surface of the control module housing, the contact status indicator configured to display a position of the at least one line contact within the control module housing to an operator when the control module housing is installed in the motor control center.
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Type: Grant
Filed: Mar 30, 2007
Date of Patent: Aug 26, 2014
Patent Publication Number: 20080022673
Assignee: Eaton Corporation (Cleveland, OH)
Inventors: Robert A. Morris (Fayetteville, NC), Scott E. McPherren (Wauwatosa, WI), Daniel J. Leeman (Fuquay-Varina, NC)
Primary Examiner: Bradley Thomas
Application Number: 11/694,494
International Classification: H02B 5/00 (20060101); H02B 13/02 (20060101); H01H 3/20 (20060101); H02B 11/00 (20060101); H02B 1/26 (20060101); H02B 11/133 (20060101); F02D 11/02 (20060101); F02D 29/06 (20060101);